Circumferential Stiffeners for Composite Fancases

ABSTRACT

Woven preforms, for example those used for jet aircraft engine fancases, may need additional stiffeners to improve the strength and/or dynamic performance of the preform assembly, as well as to serve as attachment points. The present invention describes several improved woven preforms that include circumferential or axial stiffeners, as well as methods of manufacturing the same. One embodiment includes circumferential stiffeners added to a woven preform. Another embodiment includes sub-preforms with integral flanges that combine to make integral stiffeners. A further embodiment includes an intermediate stiffener wrapped onto a base sub-preform wrap, wherein the intermediate stiffener wrap incorporates intermediate stiffeners. Another embodiment incorporates bifurcations in one or more layers of an outermost wrap of a multi-layer fabric composite that forms a preform, wherein the bifurcated outer wrap is folded to form stiffeners that may be oriented circumferentially or axially.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to circumferential stiffeners forcomposite preforms, and more particularly for manufacturing preformsthat may be processed to form fancase preforms for jet aircraft engines.

Incorporation by Reference

All patents, patent applications, documents, references, manufacturer'sinstructions, descriptions, product specifications, and product sheetsfor any products mentioned herein are incorporated herein by reference,and may be employed in the practice of the invention.

Background of the Invention

The use of reinforced composite materials to produce structuralcomponents is now widespread, particularly in applications where theirdesirable characteristics are sought, including being light in weight,strong, tough, thermally resistant, self-supporting and adaptable tobeing formed and shaped.

In this regard, contour woven preforms are used to provide fiberreinforcement in resin transfer molded articles, for example fancasesfor jet engines. Such preforms are engineered to have a specificcross-sectional shape when they are wound onto an appropriately sizedmandrel. These shapes can generally be described as a variable thicknessbarrel section with an integral flange at either end.

Typically, such preforms consist of fabrics which are woven frommaterials such as glass, carbon, ceramic, aramid, polyethylene, and/orother materials which exhibit desired physical, thermal, chemical and/orother properties, chief among which is great strength against stressfailure. Through the use of such fabrics, which ultimately become aconstituent element of the completed composite article, the compositepreform imparts the desired characteristics of the fabrics, such as veryhigh strength, into the completed composite article. Usually particularattention is paid to ensure the optimum utilization of the propertiesfor which the fabrics have been selected.

After the desired preform has been constructed, a molding or densifyingoperation takes place where a resin matrix material may be introduced toand into the woven preform, so that typically the preform becomesencased in the resin matrix material that fills the interstitial areasbetween the constituent elements of the preform. The resin matrixmaterial may be any of a wide variety of materials, such as epoxy,phenolic, polyester, vinyl-ester, ceramic, carbon and/or othermaterials, which also exhibit desired physical, thermal, chemical and/orother properties. The materials chosen for use as the resin matrix mayor may not be the same as that of the reinforcement preform and may ormay not have comparable physical, chemical, thermal or other properties.Typically, however, they will not be of the same materials or havecomparable physical, chemical, thermal or other properties, since ausual objective sought in using composites in the first place is toachieve a combination of characteristics in the finished product that isnot attainable through the use of one constituent material alone. Socombined, the woven preform and the matrix material may then be curedand stabilized in the same operation by thermosetting or other knownmethods, and then subjected to other operations toward producing thedesired component. It is significant to note at this point that afterbeing so cured, the then solidified mass of the matrix material normallyis very strongly adhered to the reinforcing material (e.g., the wovenpreform). As a result, stress on the finished component, particularlyvia its matrix material acting as an adhesive between fibers, may beeffectively transferred to and borne by the constituent material of thepreform.

Fancases for jet engines, such as the example shown in FIG. 1, usingcontour woven preforms that provide fiber reinforcement, and thenimpregnated for example by resin transfer molding, are already known inthe art. Use of this type of preform offers several advantages, some ofwhich are: provide continuous fiber in the circumferential and axialdirections; minimize touch labor through the elimination of cutting anddarting; and minimize process waste by eliminating the need for cuttingand darting.

SUMMARY OF THE INVENTION

However, while current woven preforms are adequate for manyapplications, there are situations in which a fancase requiresadditional circumferential or axial stiffeners at one or more axiallocations. Therefore, it would be an advancement in the state of the artto provide a contour woven preform enhanced with intermediatecircumferential stiffeners that are used to improve the strength and/ordynamic performance of the preform. When used for a fancase, suchstiffeners may also serve as attachment points for the fancase itself orfor attaching auxiliary equipment. This disclosure describes severalimproved preform assemblies that include circumferential stiffeners, aswell as methods of manufacturing the same.

One exemplary embodiment of the present invention is a woven preformcomprised of one or more wraps of a continuous single-layer ormulti-layer fabric to form a barrel-shaped circumference, or a ring,around a centerline of an appropriately designed mandrel. The wraps offabric can form an integral flange disposed on a first edge of the wovenfabric that forms a first edge circumference around the centerline. Thewraps of fabric can also form an integral flange disposed on a secondedge of the woven fabric that forms a second edge circumference aroundthe centerline.

While the wraps of fabric are described as forming a “barrel-shaped”circumference, the preforms are generally configured as a cylinder withcylinder walls that may bulge out, bulge in, or may bulge out in someareas and bulge in at others. Throughout this disclosure, the termsbarrel, barrel-shaped, and variations there of, are used in accordancewith this description of the variations in the preform shape.

Stiffeners, flanges, or both stiffeners and flanges, may be formed onthe outer surface of the preform by at least partially circumferentiallywrapping one or more layers of woven fabrics around the preform.Stiffeners may be formed at a location between the first and secondfabric edges of the preform; and flanges may be formed at the edges ofthe preform. One or more circumferential stiffeners may be formed fromseparate contour woven fabrics and are adjacent to and in contact with,or abutting, the barrel-shaped circumference of the preform around thecenterline. One or more circumferential stiffeners and/or one or moreflanges may be formed from fabrics comprising stretch broken fibers inthe warp direction, the weft direction, or in both the warp and weftdirections.

The invention according to one embodiment forms one or morecircumferential stiffeners comprised of one or more wraps of asingle-layer fabric.

The invention according to one embodiment forms one or morecircumferential stiffeners comprised of one or more wraps of amulti-layer fabric.

The invention according to one embodiment forms one or morecircumferential stiffeners comprised of one or more layers of contourwoven fabric.

The invention according to one embodiment forms one or morecircumferential stiffeners comprised of one or more layers of a singleor multi-layer woven fabric comprising stretch broken fibers in thewarp, weft, or warp and weft directions.

The invention according to one embodiment further comprises a preformwith one or more circumferential stiffeners wherein one or more lengthsof woven material are inserted at a bias between layers of the contourwoven fabric.

The invention according to one embodiment further comprises a preformwith one or more circumferential stiffeners affixed to the preform priorto molding, and the stiffener sections and/or the preform layersthemselves reinforced through T-forming (see U.S. Pat. No. 6,103,337,the content of which is which is incorporated herein by reference),tufting, stitching or other techniques known to those in the art.

The invention according to one embodiment comprises woven fabrics madefrom material selected from the group consisting of aramid, carbon,nylon, rayon, polyester, and glass fibers.

One exemplary embodiment of the present invention is a woven preform,suitable, for example, for a composite fancase, with a first sub-preformcomprising one or more wraps of a continuous woven fabric to form, forexample, a barrel-shaped circumference, or ring, around a centerline ofan appropriately designed mandrel. The wraps of fabric can form anintegral flange disposed on a first edge of the woven fabric that formsa first edge circumference around the centerline. The wraps of fabriccan also form an integral flange disposed on a second edge of the wovenfabric that forms a second edge circumference around the centerline. Atleast two second, or outer, sub-preforms are formed on the substantiallybarrel-shaped circumference of the first sub-preform. Each of the secondsub-preforms is comprised of one or more wraps of a continuous wovenfabric to form at least one barrel-shaped circumference around thecenterline of the first sub-preform. The wraps of fabric of the secondsub-preforms can form a first outer sub-preform integral flange disposedon a first edge of the outer sub-preform fabric that forms a first edgecircumference around the centerline, as well as a second outersub-preform integral flange disposed on a second edge of the outersub-preform woven fabric that forms a second edge circumference aroundthe centerline. The substantially barrel-shaped circumference of eachouter, or second, sub-preform wraps around the first sub-preform'ssubstantially barrel-shaped circumference. The second sub-preformintegral flanges may form integral stiffeners. Second sub-preformintegral flanges may be in contact with, or abutting, other flanges andmay, in combination, be considered integral stiffeners.

The invention according to one embodiment forms one or morecircumferential stiffeners from the flanges of adjacent secondsub-preforms. According to some embodiments, lengths of woven materialmay be inserted at a bias between adjacent flanges of some of thesub-preforms.

The invention according to one embodiment has the first sub-preformassembled before the outer sub-preforms are assembled to be in contactwith the first sub-preform's substantially barrel-shaped circumference.

The invention according to one embodiment has the first sub-preformassembled and molded before the outer sub-preforms are assembled to bein contact with the first sub-preform's substantially barrel-shapedcircumference.

One exemplary embodiment of the present invention provides a wovenpreform comprising a sub-preform of one or more wraps of a continuoussingle-layer or multi-layer woven fabric to form a substantiallybarrel-shaped circumference around a centerline. The wraps can form afirst integral flange disposed on a first edge of the woven fabric thatforms a first edge circumference around said centerline and can form asecond integral flange disposed on a second edge of the woven fabricthat forms a second edge circumference around the centerline.Intermediate stiffeners may be comprised of one or more wraps of acontinuous single-layer or multi-layer woven fabric forming intermediatestiffeners about the substantially barrel-shaped circumference aroundthe centerline. The layers of woven fabric forming the intermediatestiffeners wrap may have a first intermediate stiffener integral flangedisposed on a first edge of the intermediate stiffener wrap of wovenfabric and a second intermediate stiffener integral flange disposed on asecond edge of the intermediate stiffener wrap of woven fabric thatforms a second edge circumference around the centerline. Theintermediate stiffener wraps may incorporate one or more intermediatestiffeners disposed between the first intermediate stiffener integralflange and the second intermediate stiffener integral flange. The layersof woven fabric that form the intermediate stiffeners wrap barrel-shapedcircumference wraps around the sub-preform barrel-shaped circumference.

The invention according to one embodiment further comprises a preformwith one or more circumferential stiffeners affixed to the preform priorto molding, and the stiffener sections and/or the preform layersthemselves reinforced through T-Forming, tufting, stitching, or othertechniques known to those in the art.

An embodiment of the invention forms a composite fancase comprising oneor more wraps of a continuous single-layer or multi-layer woven fabricto form a substantially barrel-shaped circumference around a centerlineof an appropriately designed mandrel. The wraps may have a firstintegral flange disposed on a first edge of the woven fabric that formsa first edge circumference around the centerline and may have a secondintegral flange disposed on a second edge of the woven fabric that formsa second edge circumference around the centerline. An outermost wrap ofthe multi-layer woven fabric may be bifurcated in the outer surfacelayer, and the bifurcated outer surface layer may be folded up to make astiffener. The bifurcation of the outermost wrap of the outermost layermay be made in the warp direction or in the weft direction to providestiffeners in the circumferential or axial direction, respectively.

The invention according to one embodiment forms one or more stiffenersthat are oriented axially with the centerline.

The invention according to one embodiment forms one or more stiffenersthat are oriented circumferentially with the centerline.

The invention according to one embodiment forms one or morecircumferential stiffeners that are in contact with the substantiallybarrel-shaped circumference.

An embodiment of the invention includes a method of manufacturing awoven preform comprising the steps of wrapping a continuous single-layeror multi-layer woven fabric one or more times around a centerline toform a circumference around the centerline, and wrapping one or morecircumferential stiffeners around the continuous woven fabric so thatthe circumferential stiffeners form a circumference around thecenterline.

The invention according to one embodiment further comprises a preformwith one or more circumferential stiffeners affixed to the preform priorto molding, and the stiffener sections and/or the preform layersthemselves are reinforced through T-Forming, tufting, stitching, orother techniques known to those in the art.

The invention according to one embodiment molds the continuous wovenfabric after it has been wrapped one or more times around a centerlineto form a circumference around the centerline.

The invention according to one embodiment co-molds one or morecircumferential stiffeners with the continuous woven fabric after theyhave been wrapped one or more times around a centerline to form acircumference around the centerline.

The invention according to one embodiment molds circumferentialstiffeners onto the molded continuous woven fabric.

An embodiment of the invention includes a method of manufacturing awoven preform comprising the steps of wrapping a continuous single-layeror multi-layer woven fabric one or more times around a centerline toform a circumferential surface around the centerline, and at leastpartially wrapping one or more circumferential stiffeners upon thecircumferential surface to form an arc around the centerline.

An embodiment of the invention includes a method of manufacturing awoven preform comprising the steps of wrapping a continuous single-layeror multi-layer woven fabric one or more times around a centerline toform a first sub-preform that forms a circumference around thecenterline, wherein the first sub-preform may have a first integralflange disposed on a first edge of the woven fabric that forms a firstedge circumference around the centerline and may have a second integralflange disposed on a second edge of the woven fabric that forms a secondedge circumference around the centerline, wrapping one or moreadditional sub-preforms that have a first outer sub-preform integralflange disposed on a first edge of the outer sub-preform woven fabricthat forms a first edge circumference around the centerline and a secondouter sub-preform integral flange disposed on a second edge of the outersub-preform woven fabric that forms a second edge circumference aroundthe centerline, and forming integral stiffeners by aligning eachadjacent outer sub-preform integral flange so that the adjacent outersub-preform integral flanges are in contact with, or abutting, eachother.

An embodiment of the invention includes a method of manufacturing awoven preform comprising the steps of wrapping a continuous single-layeror multi-layer woven fabric one or more times around a centerline toform a sub-preform that forms a circumference around the centerline,wherein the sub-preform may have a first integral flange disposed on afirst edge of the woven fabric that forms a first edge circumferencearound the centerline and may have a second integral flange disposed ona second edge of the woven fabric that forms a second edge circumferencearound the centerline, forming intermediate stiffeners in anintermediate stiffener wrap, and wrapping the intermediate stiffenerwrap around the sub-preform.

An embodiment of the invention includes a method of manufacturing awoven preform comprising the steps of wrapping a continuous single-layeror multi-layer woven fabric one or more times around a centerline toform a circumference around the centerline, bifurcating the outermostlayer of the outermost wrap of the single-layer or multi-layer wovenfabric, and folding the bifurcated layers to make a circumferentialstiffener.

Therefore, an object of the invention is to provide woven preformassemblies incorporating circumferential stiffeners useful, for example,in forming jet engine fancases.

An additional object of the invention is to provide methods ofmanufacturing the woven preform assemblies incorporating circumferentialstiffeners, useful, for example, in forming jet engine fancases.

For a better understanding of the invention, its operating advantagesand specific objects attained by its uses, reference is made to theaccompanying descriptive matter in which preferred, but non-limiting,embodiments of the invention are illustrated.

Terms “comprising” and “comprises” in this disclosure can mean“including” and “includes” or can have the meaning commonly given to theterm “comprising” or “comprises” in US Patent Law. Terms “consistingessentially of” or “consists essentially of” if used in the claims havethe meaning ascribed to them in US Patent Law. Other aspects of theinvention are described in or are obvious from (and within the ambit ofthe invention) the following disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention, are incorporated in and constitute apart of this specification. The drawings presented herein illustratedifferent embodiments of the invention and together with the descriptionserve to explain the principles of the invention. In the drawings:

FIG. 1 shows a known prior art fancase fabricated using a contour wovenfiber preform;

FIG. 2 shows a schematic of a known prior art contour woven fancasepreform;

FIG. 3 shows an assembly of contour woven stiffeners added to a wovenpreform according to an embodiment of the invention;

FIG. 4 shows stiffeners formed by combining multiple sub-preforms withthe woven preform according to an embodiment of the invention;

FIG. 5 shows multiple stiffeners in a single sub-preform formedaccording to an embodiment of the invention;

FIG. 6 shows an integral stiffener formed by bifurcating the outermostlayer of the outermost wrap of one of the multi-layer fabrics used toform a woven preform according to an embodiment of the invention; and

FIG. 7 shows various shapes of woven preforms that may be producedaccording to the embodiments of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The instant invention will now be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theillustrated embodiments set forth herein. Rather, these illustratedembodiments are provided so that this disclosure will be thorough andcomplete, and will fully convey the scope of the invention to thoseskilled in the art.

In the following description, like reference characters designate likeor corresponding parts throughout the figures. Additionally, in thefollowing description, it is understood that such terms as “upper,”“lower,” “top” and “bottom” and the like are words of convenience andare not to be construed as limiting terms.

As described herein, circumferential stiffeners are incorporated into anassembly of woven preforms, often suitable for use as composite fancasesfor jet engines, which are generally cylindrical or substantially“barrel shaped”. While the assembly of woven preforms is described as“barrel-shaped”, the preforms are generally configured as a cylinderwith a cylinder wall that may bulge out, bulge in, or may bulge out insome areas and bulge in at others, such as those shown in FIG. 7, forexample. Throughout this disclosure, the terms barrel, barrel-shaped,and variations there of, are used in accordance with this description ofthe variations in the preform shape.

In other words, the fancases have a center line and the woven preformassemblies, also comprising the circumferential stiffeners, make acircumference around the center line of an appropriately designedmandrel for fabrication of the fancase. These stiffeners provideincreased strength to the fancase and can also provide attachment pointsfor mounting other pieces of equipment to the fancase by, for example,bolting such equipment to the circumferential stiffener. Additionally,such stiffeners may also be used for mounting the fancase to, forexample, structural components. The assembly of woven preforms withcircumferential stiffeners may be useful as fancase preforms for jetaircraft engines.

Turning to the figures, FIG. 1 shows a prior art fancase (100)fabricated using a known contour woven fiber preform. The fancase (100)of FIG. 1 includes a substantially barrel-shaped body (101). Thebarrel-shaped body (101) may include barrel sections of variablethickness. At either end of the barrel-shaped body (101) are integralflanges (102) and (103) that are formed from the woven preform. The pathof the warp fibers (running in the circumferential direction) areengineered to have the proper lengths in the final shaped configurationwithout the need for cutting and darting. These integral flanges providecircumferential stiffening of the preform. However, while the fancase(100) of FIG. 1 is adequate for many applications, there are also timeswhere it is desirable or necessary to incorporate additionalcircumferential stiffeners at one or more axial locations. Suchadditional circumferential stiffeners are used to improve the strengthand/or dynamic performance of the fancase. Additionally, circumferentialstiffeners may serve as attachment points, for example for auxiliaryequipment.

FIG. 2 is a schematic, or partial cross-section of a prior art fancasepreform, like that of FIG. 1, which exemplifies current technology. Forconvenience, only one half of the preform is shown and the barrelsection is illustrated with a constant thickness. In FIG. 2, a crosssection of the preform is shown consisting of four continuous wraps(202), (203), (204), and (205) of woven fabric that trace acircumference around centerline (201) of an appropriately designedmandrel. In other words, in FIG. 2 the end of the first wrap (202)connects to the beginning of the second wrap (203), the end of thesecond wrap (203) connects to the beginning of the third wrap (204), theend of the third wrap (204) connects to the beginning of the fourth wrap(205), etc. Additionally, this fabric does not have to be a uniformthickness and the body (101) of the preform between the flanges (102),(103) does not have to be cylindrical (e.g., can be substantiallybarrel-shaped or other shapes shown in FIG. 7, for example). While FIG.2 shows four wraps of this continuous woven fabric, a final preform mayhave any number of wraps.

Typically, the fabrics used for such preforms are woven on a loom fittedwith a special takeup system that allows warp fibers to have differentlengths. The warp fibers are in the circumferential direction of thefancase. The paths of the warp fibers are engineered to have the properlengths in the final shaped configuration without the usual need for anycutting and/or darting, resulting in a contour woven fabric. The fabricmay be single-layer or multi-layer.

Fibers or yarns typically used to weave the fabrics for such preformsmay comprise one or more materials selected from the group consisting ofaramid, carbon, nylon, rayon, polyester, and glass fiber.

Embodiments of the invention may be useful in the fabrication offancases for jet engines, typically used in aircraft. In the followingdiscussion, the preform assembly may be referred to as a fancase preformas an illustrative use for the inventive preform assembly, not as alimitation. One of ordinary skill in the art will recognize other usesfor the disclosed woven preform assemblies which would take advantage ofthe enhanced performance characteristics provided by the inventivepreform assembly.

An embodiment provides a preform assembly by a method of addingadditional circumferential stiffeners to a contour woven preformassembly. In this embodiment, layers of woven fabric are wrapped aroundan appropriately designed mandrel to form a fancase preform like thatshown in FIG. 2. An example of this is shown schematically in FIG. 3,which also depicts two single- or multi-layer woven fabrics at leastpartially wrapped around the circumference of the wraps of the contourwoven fabric, forming circumferential stiffeners (301) and (302). Thequantity, relative shapes, and sizes of such woven circumferentialstiffeners are not intended to be limited by the exemplary schematic inFIG. 3. The individual circumferential stiffeners need not be similar inshape or size to one another. Also, the body (101) of the preformbetween the flanges (102), (103) does not have to be cylindrical and canhave a substantially barrel shape (101). It can also be of non-uniformthickness.

The woven fabric used to form the stiffeners (301), (302) may be acontour woven fabric in which the length of the warp fibers can bevaried across the width of the fabric. The varied lengths are engineeredto allow the stiffener to be positioned in its final shapedconfiguration.

In other embodiments, the fabric used to form the stiffeners (301),(302) is composed of stretch broken (SB) fibers in at least the warp(circumferential) direction of the stiffener. However, these SB fibers,for example, carbon, may also be used in the weft (axial) direction, orboth. The stretch broken fibers also allow the stiffener to bepositioned in its final shaped configuration.

The circumferential stiffeners (301), (302) may be built up usingmultiple wraps of a single-layer fabric, or perhaps a lesser number ofwraps when using a multi-layer woven fabric. Regardless of this, thecircumferential stiffeners can be wound onto/over the dry base preformalready on the mandrel and co-molded, or they can be wound onto a moldedfancase preform already on the mandrel and molded in a secondaryoperation forming the final composite.

The circumferential stiffeners (301), (302) may include lengths ofadditional woven material that is inserted between the layers of thewoven fabric if desirable, as it is wound about the circumference of thepreform base such that the yarns of the inserted material are at anangle of orientation (on a bias) to the yarns of the fabric layersforming the stiffeners. Such “bias” fabrics could also be insertedbetween the wraps of fabric (202-205) as they are wound about themandrel. Furthermore, additional through-thickness reinforcement of thepreform assembly can be provided by, for example, T-forming, tufting, orstitching through the stiffeners themselves and/or to attach thestiffener layers (301, 302) to the preform layers (202-205) prior tomolding and resin impregnation. The circumferential stiffeners (301),(302) may extend only partially around the circumference of the fancasepreform (100). Partially extending stiffeners (301), (302) may also beT-formed, tufted, or stitched through the layers themselves or onto thedry base fancase preform prior to molding to provide through thicknessreinforcement to the body (101) of the preform (100).

In addition, the stiffeners can be complete circumferential rings, orthey may be only are segments that do not wrap around the fullcircumference of the preform, or they may be a combination of completecircumferential rings and are segments. For example, arc segments are abeneficial option when the circumferential stiffeners are used forequipment mounting points that do not require full circumferentialrings. In this case, the preform assembly will also comprise sections ofthe woven fabric that are cut to length and may be stacked on top of oneanother, to the extent necessary, to build up the thickness of the arcsegment.

Thus, the circumferential stiffeners can be multiple wraps of asingle-layer fabric, multiple wraps of a multi-layer fabric, fullcircumferential rings, partial stiffeners (i.e., arcs), and they may bewound onto the circumferential surface of the contour woven basepreform, with or without T-forming, tufting or stitching, and co-molded.Alternately they may be wound onto the circumferential surface of thealready molded preform base, and molded in a secondary operation formingthe final composite. Different fabrics may also be selected for eachcircumferential stiffener, and the fabrics forming the circumferentialstiffeners and the base preform need not be the same type of fabric.Additionally, the fabrics used do not have to be a uniform thickness,but may have thicker or thinner regions as required.

Another embodiment of a composite fancase with additionalcircumferential stiffeners is shown in FIG. 4, which shows an exemplaryembodiment that uses several woven sub-preforms, each of which mayinclude one or more wraps around an appropriately designed mandrel. Thewoven sub-preforms may be formed from a fabric at least partially wovenfrom stretch-broken fibers or yarns or may be formed from contour wovenfabric. In FIG. 4, the first sub-preform includes wraps (202) and (203)of a contour woven fabric around an appropriately designed mandrel.Outer sub-preforms include multiple wraps of woven fabrics asdemonstrated by a second sub-preform including wraps (401) and (402), athird sub-preform including wraps (403) and (404), and a fourthsub-preform including wraps (405) and (406).

All of the sub-preforms are fabricated and combined to make the finalfancase preform assembly. Each of these sub-preforms consists of a basesection with integral flanges and/or stiffeners at either end. Anintegral stiffener is one whose layer or layers have through fibersconnecting it to the base. An intermediate stiffener is located in oneor more locations between the end flanges. Intermediate stiffeners maybe integral or not. The number of wraps used for any or all of thesub-preforms can be varied, and are not intended to be limited by theexemplary schematic shown in FIG. 4. Similarly, the relative shapes andsizes of such contour woven fabric sub-preforms are not intended to belimited by the exemplary schematic in FIG. 4. Additionally, the wovenfabrics used do not have to be a uniform thickness, but may have thickeror thinner regions as desired. Also, the body (101) of the preformbetween the flanges (102), (103) does not have to be perfectlycylindrical (e.g., can be substantially barrel-shaped or any shape shownin FIG. 7, for example) or of uniform thickness. Different fabrics mayalso be selected for each sub-preform.

In this embodiment, the first sub-preform containing wraps (202) and(203) is very similar to the basic preform shown in FIG. 2, except thatit does not have as many wraps and only accounts for part of the fullthickness of the preform. Two or more other sub-preforms, called outersub-preforms—such as those in FIG. 4 that include wraps (401) and (402),wraps (403) and (404), and wraps (405) and (406)—are wound over thefirst sub-preform that includes wraps (202) and (203). Thus, thecombination of all of the sub-preforms completes the full thickness ofthe substantially barrel-shaped body (101) of the preform assembly, aswell as the thickness of the integral flanges (102) and (103) that areformed by those sub-preforms whose integral flanges are aligned on anouter edge. The other integral flanges of these sub-preforms combine tomake the integral stiffeners (407) and (408) that are disposed betweenthe integral flanges (102) and (103) on the barrel-shaped body (101) ofthe preform assembly. Circumferential stiffeners like those described inthe first embodiment and illustrated in FIG. 3 may also be incorporatedinto this embodiment.

Lengths of woven material (not shown) may be placed between the integralflanges of any of the sub-preforms illustrated, for example, in FIG. 4.For example, one or more lengths of woven material may be placed betweenthe integral flanges formed by wraps 405 and 406 in one outersub-preform. One or more lengths of woven material may also be placedbetween wraps 403 and 405 of adjacent outer sub-preforms, or betweenwrap 405 and integral flange 103 of the first sub-preform, or betweenflange 102 and wrap 401. These reinforcement layers therefore can beplaced between the layers of any of the wraps 101-406, and within any ofthe layers forming the flanges 102, 103, 407, and 408. These additionalwoven layers are inserted such that the yarns of the inserted materialare at an angle of orientation greater than 0 degrees and less than 90degrees (i.e., on a bias) to the yarns of the fabric layers forming thestiffeners or sub-preforms. Furthermore, additional through-thicknessreinforcement of the preform assembly can be provided by, for example,T-forming, tufting, or stitching through the stiffeners (407-408) andthe bias fabrics themselves, the flange layers (102-103), and/or toattach the stiffener layers to the preform layers (202-203) prior tomolding and resin impregnation. The fabrics forming the stiffeners mayalternatively be wound or placed onto the circumferential surface of thealready molded preform base, and molded in a secondary operation,forming the final composite.

The widths of the base sections for each sub-preform and outersub-preforms can be designed to position the integral stiffeners attheir desired axial locations. One or more integral stiffeners can beformed, based on the number of outer sub-preforms used. Additionally,and similar to the previous embodiments, all of the sub-preforms can beassembled and molded in one operation. Alternately, the outermostsub-preforms can be wrapped or placed onto the circumference of a moldedbase preform already on a mandrel and molded in a secondary operationforming the final composite.

An additional embodiment is shown in FIG. 5. In this non-limitingexample, the base preform is a sub-preform that includes three wraps(202), (203), and (204) about an appropriately designed mandrel of asingle-layer or multi-layer contour woven fabric with flanges at eachend. An additional wrap, called the intermediate stiffener wrap, forms asub-preform (501) which incorporates one or more intermediate stiffeners(502) and (503). The intermediate stiffener wrap is incorporated into asingle fabric that provides the last wrap of the complete preform.Sub-preform 501 may be formed from a contour woven fabric, or may beformed from a fabric at least partially woven from stretch-brokenfibers. This sub-preform (501) is wound onto the base sub-preform wraps(202), (203), and (204)—which generally provide the majority of thematerial for the preform assembly—and thus completes the preform. Thequantity, relative shapes, and sizes of such intermediate stiffeners arenot intended to be limited by the exemplary schematic in FIG. 5.

Lengths of woven material (not shown) may be placed between the integralflanges of the sub-preform 501 and the flanges of the barrel shaped body101 as illustrated, for example, in FIG. 5. For example, one or morelengths of woven material may be placed between the integral flangesformed in the intermediate stiffener wrap preform 501 and flange layer102 of the barrel shaped body 101. Similarly, one or more lengths ofwoven material may be placed between the integral flanges formed in theintermediate stiffener wrap preform 501 and flange layer 103 of the body101. In some embodiments, one or more lengths of woven material may alsobe placed within the folds of one or more intermediate stiffeners (502)and (503).

These additional woven layers are inserted such that the yarns of theinserted material are at an angle of orientation greater than 0 degreesand less than 90 degrees (i.e., on a bias) to the yarns of the fabriclayers forming the flanges or stiffeners. Furthermore, additionalthrough-thickness reinforcement of the preform assembly can be providedby, for example, T-forming, tufting, or stitching through theintermediate stiffeners (502,503) and the woven fabrics themselves, theflange layers (102-103), and/or attach the stiffener layers to thepreform layers (202-203) prior to molding and resin impregnation. Thefabrics forming the stiffeners may alternatively be wound or placed ontothe circumferential surface of the already molded preform base, andmolded in a secondary operation forming the final composite.

The number of wraps used for sub-preform can be varied, and are notintended to be limited by the exemplary schematic shown in FIG. 5.Additionally, the fabrics used do not have to be a uniform thickness,but may have thicker or thinner regions as desired. Also, the body (101)of the preform between the flanges (102), (103) does not have to beperfectly cylindrical, but can be substantially barrel-shaped. Differenttypes of fabrics may also be selected for the sub-preform and theintermediate stiffener wrap. Circumferential stiffeners like thosedescribed in the first embodiment may also be incorporated into thisembodiment.

Another embodiment is illustrated in FIG. 6, which introduces abifurcation (603) of the outermost layer of the outermost wrap (602) ofthe multi-layer woven fabric. As with the prior art embodiment in FIG.2, the preform is constructed with a number of continuous wraps of wovenfabric (607) that is wrapped one or more times about an appropriatelydesigned mandrel to construct the preform assembly (608). FIG. 6 showsfour wraps of fabric starting with an innermost wrap (601), intermediatewraps (609) and (610), and an outermost wrap (602). The outermost wrap(602) includes bifurcated portions (604) and (605) that are formed inthe outer layer of the outermost wrap. The outer layer of the outermostwrap may be bifurcated in the warp direction. The bifurcated layer ofsaid outer surface layer is then folded up to make a circumferentialstiffener. The circumferential stiffener can act as an attachment pointfor bolting a piece of equipment to the molded preform assembly whenused as a fancase, as an example. The stiffener may encompass only anare segment around the circumference (606), or the wrap may be formedlong enough to allow a full circumferential ring round the fancasepreform.

The bifurcation (603) may also be made in the weft direction, in amanner that allows for axial stiffeners or attachment points as well. Insuch a case, the bifurcation would be made in the weft, rather than thewarp, direction of the single-layer or multi-layer fabric. As above, theoutermost layer is folded up to make an axial stiffener.

The number of wraps used can be varied, and are not intended to belimited by the exemplary schematic shown in FIG. 6. Additionally, thefabrics used do not have to be a uniform thickness, but may have thickeror thinner regions as required. Also, the body (e.g., (101) in FIG. 2)of the preform created with the embodiment shown in FIG. 6 that isbetween the flanges (e.g., (102) and (103) in FIG. 2) does not have tobe perfectly cylindrical, but can be substantially barrel-shaped. Nordoes it have to be of uniform thickness. Circumferential stiffeners likethose described in the first embodiment may also be incorporated intothis embodiment.

Lengths of woven material (not shown) may be placed between thebifurcated portions (604, 605) when the bifurcated portions are foldedto form a stiffener as illustrated in FIG. 6. For example, one or morelengths of woven material may be placed between the bifurcated portions(604, 605) as illustrated in section A-A of FIG. 6. These additionalwoven layers are inserted such that the yarns of the inserted materialare at an angle of orientation greater than 0 degrees and less than 90degrees (i.e., on a bias) to the yarns of the bifurcated fabric layersforming the stiffeners. Furthermore, additional through-thicknessreinforcement of the preform assembly can be provided by, for example,T-forming, tufting, or stitching through the stiffeners (604, 605) andthe woven fabrics themselves, prior to molding and resin impregnation.The assembly is then molded into the final composite.

In all the embodiments, once the preform assembly is formed, resin isinfused into the preform assembly (in one or two steps as indicated) byone of the methods known to those skilled in the art, and cured. Theinfusion of resin, known as a molding or densifying operation,introduces a matrix material to and into the woven preform, so that theresin matrix fills, or substantially fills, the interstitial areasbetween the components of the preform, encasing the components and thepreform. The resin matrix material may be any of a wide variety ofmaterials, such as epoxy, phenolic, polyester, vinyl-ester, ceramic,carbon and/or other materials, which also exhibit desired physical,thermal, chemical and/or other properties. The materials chosen for useas the resin matrix may or may not be the same as that of thereinforcement preform and may or may not have comparable physical,chemical, thermal or other properties. Following the molding process,the composite is then removed from the mandrel, and any finishingoperations, such as trimming or polishing, etc., are performed.

Thus, by the present invention, its objects and advantages are realized,and although preferred embodiments have been disclosed and described indetail herein, its scope and objects should not be limited thereby;rather its scope should be determined by that of the appended claims.

What is claimed is:
 1. A woven preform assembly comprising: a firstsub-preform comprising one or more wraps of a continuous woven fabricabout a centerline or an appropriately designed mandrel to form at leastone substantially barrel-shaped circumference around the centerline,wherein said wraps have a first integral flange disposed on a first edgeof said woven fabric that forms a first edge circumference around saidcenterline and a second integral flange disposed on a second edge ofsaid woven fabric that forms a second edge circumference around saidcenterline; at least two outer sub-preforms, each of said outersub-preforms comprising: one or more wraps of a continuous woven fabricabout the centerline to form at least two substantially barrel-shapedcircumferential surfaces around said centerline, wherein said wraps havea first outer sub-preform integral flange disposed on a first edge ofsaid outer sub-preform woven fabric that forms a first outer sub-preformedge circumference around said centerline and a second outer sub-preformintegral flange disposed on a second edge of said outer sub-preformwoven fabric that forms a second edge circumference around saidcenterline; each said outer sub-preform substantially barrel-shapedcircumference wraps around said first sub-preform substantiallybarrel-shaped circumference; and adjacent outer sub-preform integralflanges are in contact with each other and comprise integral stiffeners.2. The preform assembly of claim 1, further comprising: one or morecircumferential stiffeners in contact with said outer sub-preform atsaid outer sub-preform substantially barrel-shaped circumference.
 3. Thepreform assembly of claim 1, wherein each sub-preform woven fabric ismade from materials selected from the group consisting of carbon, nylon,rayon, polyester, glass, ceramic, aramid, and polyethylene.
 4. Thepreform assembly of claim 1, wherein said first sub-preform is assembledand molded before said outer sub-preforms are assembled to be in contactwith said first sub-preform barrel-shaped circumference.
 5. The preformassembly of claim 1, wherein said first sub-preform and secondsub-preform are co-molded.
 6. The preform assembly of claim 1, whereinat least some of said outer sub-preforms are affixed to said firstsub-preform by T-forming, tufting, or stitching.
 7. The preform assemblyof claim 1, further comprising one or more lengths of woven materialinserted at a bias between said wraps of continuous woven fabric.
 8. Thepreform assembly of claim 1, further comprising lengths of wovenmaterial inserted at a bias between at least some of said adjacent outersub-preform integral flanges.
 9. The preform assembly of claim 1,wherein first outer sub-preform integral flange is arranged adjacent tofirst integral flange and second outer sub-preform integral flange isarranged adjacent to second integral flange.
 10. The preform assembly ofclaim 9, further comprising lengths of woven material inserted at a biasbetween at least one of said first outer sub-preform integral flange andsaid first integral flange and said second outer sub-preform integralflange and said second integral flange.
 11. The preform assembly ofclaim 1, wherein said fabric may be selected from the group consistingof single-layer fabric and multi-layer fabric.
 12. The woven preformassembly according to claim 1, wherein said continuous woven fabric is acontour woven fabric.